Molex ATP-301 User Manual

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19228-0030

ATP-301 Air Tape Press

ATP-301 AIR TAPE PRESS

Order No. 19228-0030

Operation Manual For Tape Carried Products

Single or Double Space Indexing

 Description
 Operation
 Maintenance

Order No: TM-192280498 Release Date: 11-11-02 UNCONTROLLED COPY Page 1 of 42
Revision: E Revision Date: 08-25-09

ATP-301 Air Tape Press

WARNING

NEVER USE THIS TOOL WITHOUT GUARDS OR SAFETY DEVICES THAT ARE INTENDED TO

PREVENT HANDS FROM REMAINING IN THE CRIMP TOOLING AREA.

NEVER OPERATE, SERVICE, INSTALL OR ADJUST THIS TOOL WITHOUT PROPER INSTRUCTION

AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUCTIONS IN THIS
MANUAL AND ALL APPLICABLE AIR POWERED CRIMPING TOOL MANUALS.

NEVER SERVICE THIS MACHINE WHILE IT IS CONNECTED TO ANY ELECTRICAL POWER

SOURCE. DISCONNECT POWER BY UNPLUGGING THE PRESS FROM ITS POWER
SOURCE.

NEVER INSTALL OR REMOVE CRIMP TOOLING WITH THE AIR LINE CONNECTED.

NEVER OPERATE THE PRESS WITH AIR PRESSURE GREATER THAN 110 PSI (AT PRESS

REGULATOR).

CAUTION MOLEX CRIMP SPECIFICATIONS ARE VALID ONLY WHEN USING MOLEX TERMINALS AND

MOLEX APPLICATORS AND TOOLING.

WORK SAFELY AT ALL TIMES

For Service, Contact Your

Local Molex Sales Office

Molex Application Tooling Group

2200 Wellington Court

Lisle, IL 60532

Tel: [phone]

Fax: [phone]

Visit our Web site at http://www.molex.com

Order No: TM-192280498 Release Date: 11-11-02 UNCONTROLLED COPY Page 2 of 42
Revision: E Revision Date: 08-25-09

ATP-301 Air Tape Press

Table of Contents

SECTION

1 General Description

2 Installation

3 Setup - Operation

4 Maintenance

5 Parts List, Assembly Drawings, Electrical, Pneumatic and Troubleshooting

Order No: TM-192280498 Release Date: 11-11-02 UNCONTROLLED COPY Page 3 of 42
Revision: E Revision Date: 08-25-09

ATP-301 Air Tape Press

1.1. Description

1.2. Features

1.3. Technical Specifications

1.4. Delivery Check

1.5. Tools

Section 1

General Description

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Revision: E Revision Date: 08-25-09

ATP-301 Air Tape Press

Figure 1

-1

REEL ARM

COVER ASSEMBLY

FOOT PEDAL

MAIN AIR CYLINDER

TOP ROLLER

CONTROLS

INDEX BLOCK

RAM ASSEMBLY

LOWER CRIMP

BASE ASSEMBLY

FRAM

E

PRESS HANDLE

Principal Parts of the ATP-301 Tape Press (19228-0030)

ASSEMBLY

ASSEMBLY

ASSEMBLY

ASSEMBLY

ASSEMBLY

TOOLING ASSEMBLY

ASSEMBLY

ASSEMBLY

Order No: TM-192280498 Release Date: 11-11-02 UNCONTROLLED COPY Page 5 of 42
Revision: E Revision Date: 08-25-09

ATP-301 Air Tape Press

General Descrition

1.1. Description

The ATP-301 (19228-0030) Air Tape Press is an
economical, electrically controlled, air powered
termination machine. It is designed to provide an
effective method for low cost, high quality
terminations of tape carried products including
insulated and un-insulated terminals, quick
disconnects, and some types of splices with sizes
from 26 through 8 AWG.

Production flexibility is obtained by interchangeable
crimp tooling. Critical setup and gauging time is
eliminated because of the butting die design built in
to all the ATP-301 crimp tooling. Utilizing this
technology allows changeover of product and
tooling in only a few minutes, regardless of size or
style of product.

The ATP-301 Air Tape Press will complete one
crimping cycle with each depression of the foot
pedal. A product is terminated and advanced to
the next position for removal in approximately one
second. Double spaced products can be
processed with the flip of a switch.

1.2. Features

 Processes tape carried products including

insulated and un-insulated terminals, quick
disconnects and splices

 Double index feature for products double

spaced on tape such as large ring and spade
terminals or flag terminals

 Foot pedal actuation allows hands-free

operation

 Versatile, compact, lightweight and portable
 Overhead reel mounting requires less

workbench space

 Control panel conveniently located
 Product and tooling changeover in just minutes
 Fast and reliable. Up to 45 cycles per minute

(depending on operator skill)

1.3. Technical Specifications

Dimensions without reel mounted

Height 14.00” (355.6mm)
Width 14.00“ (355.6mm)
Depth 1100” (279.4mm)
Unpacked weight 44 lbs (97 kg)
Shipping weight 52 lbs (115 kg)

Dimensions with 24.00” (609.6mm) reel
mounted

Height 35.00” (889.0mm)
Width 39.75” (1009.6mm)

Tape reel sizes:

14.00” (355.6mm) and

24.00” (635.0mm)

Power Requirements

Voltage: 120V AC, 60 Hz

Production Rate (depending on operator skill)

Single Index: 2800 per hour
Double Index: 2500 per hour

Air Pressure

95-110PSI (At the press)
(6.55/7.58 Bar)

Air Volume

1 Press 1.5 scfm (.00071m3/s)

Lubrication Oil

40WT Non-detergent

Lubrication Grease

Permatex multi-purpose synthetic grease with
Teflon No. 82329

Service Frequency

1 month or 20,000 cycles

Processing Capability

Up to 8 AWG (8.36mm²) of copper conductor in
solid or stranded wire.

Order No: TM-192280498 Release Date: 11-11-02 UNCONTROLLED COPY Page 6 of 42
Revision: E Revision Date: 08-25-09

ATP-301 Air Tape Press

Sound Level

Operator will be exposed to less than 85 DB.

1.4. Delivery Check

19228-0030 Main press assembly
19228-0076 Reel arm assembly
69018-6237 Power cord
63800-8394 Foot pedal assembly
(attached)
TM-192280498 Instruction manual
19228-0497 Fastener kit

(Includes 64016-0068
Stripper / Wire stop assembly)

NOTE: See section 2.1 for unpacking
instructions.

1.5. Tools

The following tools are recommended for setup
and adjustments to the applicator in this press

1. Standard hex wrench set (inch)

2. Adjustable wrench

3. Wire stripper / cutter

4. Scissors

Order No: TM-192280498 Release Date: 11-11-02 UNCONTROLLED COPY Page 7 of 42
Revision: E Revision Date: 08-25-09

ATP-301 Air Tape Press

Section 2

Installation

2.1. Unpacking and Positioning the Press

2.2. Reel Arm Assembly Installation

2.3. Air Supply and Electrical Power Connection

2.4. Tape Reel Installation

2.5. Crimp Tooling Installation and Removal

2.6. Insulation Punch Adjustment

2.7. Die Spacer Installation

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Revision: E Revision Date: 08-25-09

ATP-301 Air Tape Press

CROSS MEMBER

3/8”-16 ACORN NUT

3/8”-16 THR

EADED STUD

3/8”-16 SHCS (2)

REEL SHAFT

PRESS HANDLE

AIR COUPLING

AIR LINE W/COUPLING

POWER SUPPLY

POWER CORD

FOOT PEDAL CORD

Figure 2

-2

Read the following instructions before attempting to operate tool.

2.1. Unpacking and Positioning the Press

Open the top of the shipping carton. Locate and
remove the reel arm assembly and set aside.
Remove the packaging film and foam as required to
gain access to the air press. Use the press handle
to lift the unit out of the shipping carton. As the
press is lifted with one hand, support the foot pedal
assembly with the other and place the unit on a
clean, flat surface. Remove the plastic covering
from around the air press and verify that all items
are present (See delivery check: Section 1.4).

Position the air press on top of a flat, sturdy
workbench approximately 4.00” (100mm) back from
the front edge. Check that the crimping position is
ergonomic for the operator’s size. A bench height
of 30.00 to 32.00” (762 to 813mm) should provide operator comfort and allow both feet to rest on the floor.
The foot pedal should be placed in a comfortable position. A chair or stool with an adjustable height and
backrest should be provided for maximum comfort and back support for the operator.

2.2. Reel Arm Assembly Installation (See Figure 2-1)

1. Remove the 3/8-16” acorn nut and (2) 3/8” washers from the top cover.

2. Locate the reel arm assembly and disassemble the cross member by removing (2) 3/8” SHCS. Reposition
the cross member in a horizontal position extending to the left side with the reel shaft oriented to the front
and replace the (2) 3/8” SHCS and tighten securely.

3. Place the reel arm assembly over the 3/8-16” stud on the top of the cover, and replace the 3/8-16” acorn
nut and tighten securely. The (2) 3/8”
washers are not required for mounting the
reel arm to the press but may be required
for future use if the reel arm assembly is
removed and the press is to be transported.

2.3. Air Supply and Electrical Power Connection

(See Figure 2-2)

1. Connect the air supply hose to the
filter/regulator located on the rear of the
press cover. A standard 1/4” NPT quick-
change air coupler compatible with your
quick connect brand should be mounted. A
1/4” minimum diameter air hose should be
used to satisfy the 1.5 CFM air volume
requirement for the ATP-301.

2. Connect the appropriate end of the power
cord to the socket of the ATP-301 power
supply module. The power supply module is located at the end of the power cord that extends out the
rear of the machine.

Figure 2-1

Order No: TM-192280498 Release Date: 11-11-02 UNCONTROLLED COPY Page 9 of 42
Revision: E Revision Date: 08-25-09

ATP-301 Air Tape Press

REEL SHAFT

THUMB SCREW

DISC

QUICK RELEASE PIN

LOGO FACING

TAPE REEL

Figure 2

-3

CRIMP TOOLING MTG

INSULATION ADJ. CAM

UPPER PUNCH HOLDER

LOWER ANVIL

SAFETY SHEILD

THUMB SCREW

Figure 2

-4

INSULATION ANVIL (I1)

INSULATION PUNCH (I2)

CONDUCTOR PUNCH (E2)

DIE SPACERS (IF REQUIRED)

3. Connect the appropriate end of the power cord to a grounded electrical outlet (120V AC).

2.4. Tape Reel Installation (See Figure 2-3)

1. Pull the quick release pin from the end of the reel shaft & remove.

2. Loosen the thumbscrew on the disc assembly and remove from the
reel shaft.

3. Place the tape-fed terminals reel over the reel shaft. Be certain to orient
the reel so the MOLEX logo is facing forward.

4. Place the disc assembly back on the reel shaft and push toward the

ASSEMBLY

reel until there is enough force applied to keep the reel from rotating
freely and lock in position by tightening the thumbscrew.

NOTE: For precise setting of the tension, unwind a length of terminals from
the reel to the top of the work surface. With a full reel of product, this is the
maximum amount of resistance the disc assembly will be required to
balance.

2.5. Crimp Tooling Installation and Removal (See Figure 2-4)

Conductor and Insulation Punches (E2 and I2) (Upper Tooling)

CAUTION: Always disconnect power and air supply before installing or removing tooling.

(SET AT “L” LARGE SETTING)

SCREWS #10-32 SHCS

(BY LENGTH REQUIRED)

CONDUCTOR ANVIL (E1)

FRONT OF PRESS

HOLDER

Order No: TM-192280498 Release Date: 11-11-02 UNCONTROLLED COPY Page 10 of 42
Revision: E Revision Date: 08-25-09

ATP-301 Air Tape Press

NOTE: Always clean mounting surfaces of crimp tooling and tooling holders prior to installation.

Installation

1. Unscrew the thumbscrew and remove the safety shield.

2. Rotate the insulation adjustment cam so the arrow points to the “L” setting (largest wire insulation
diameter).

NOTE: The insulation adjustment cam MUST always be set to “L” when installing crimp punches (E2
and I2). This is to allow proper clearance to install the conductor punch (E2).

3. Place the crimp punches (E2 and I2 if required) into the upper punch holder. If the upper tooling
requires a die spacer, install as shown in Figure 2-4. Be certain to orient the punches in the proper
direction (refer to the Crimp Tooling Specification Sheet when necessary). Using a 5/32” hex wrench,
start the #10-32 SHCS but do not fully tighten. Rotate the insulation adjustment cam to the desired
position (“L”, “M”, or “S”). See Figure 2-5. Push the upper punches (E2 and I2) upward with your
fingers to ensure proper seating in the upper punch holder and tighten the #10-32 SHCS.

4. If the crimp tooling does not include an insulation punch (I2), push up on the conductor punch (E2)
and tighten the #10-32 SHCS.

Removal

1. Loosen the #10-32 SHCS.

2. If required, rotate the insulation adjustment cam to the “L” setting.

3. Unscrew the #10-32 SHCS until disengaged and remove the punches.

Conductor and Insulation Anvils (E1 and I1) (Lower Tooling)

CAUTION: Always disconnect power and air supply before installing or removing tooling

NOTE: Always clean mounting surfaces of crimp tooling and tooling holders prior to installation.

Installation

1. Lift the ram up and place the crimp anvils (E1 and I1 if required) into the lower anvil holder. If the lower
tooling requires a die spacer, install as shown in Figure 2-4. Be certain to orient the anvils in the proper
direction with the part number facing the operator (refer to the Crimp Tooling Specification Sheet when
necessary). Tighten the #10-32 SHCS.

2. Lower the ram allowing the punches and anvils to close. Crimp tooling should be aligned and engage
with no resistance. If binding occurs, loosen the (2) #10-32 SHCS. With the ram in the down position
and the tooling engaged, tighten the (2) #10-32 SHCS. If insulation tooling is installed, be certain to
push up on the insulation punch before tightening the screw.

3. Replace the safety shield and secure in position with the thumbscrew.

Removal

1. Loosen the #10-32 SHCS.

2. Lift the ram up, and unscrew the #10-32 SHCS until disengaged and remove the anvils.

Order No: TM-192280498 Release Date: 11-11-02 UNCONTROLLED COPY Page 11 of 42
Revision: E Revision Date: 08-25-09

ATP-301 Air Tape Press

RAM

“S” SETTING FOR

INSULATION CRIMP PUNCH IS IN

CRIMP PUNCH

UPPER PUNCH

“L” SETTING FOR

“M” SETTING FOR MEDIUM

INSULATION CRIMP PUNCH IS IN

INSULATION

Figure

2-5

2.6. Insulation Punch Adjustment (See Figure 2-5)

CAUTION: Always disconnect power and air supply before adjusting insulation punch.

1. Unscrew the thumbscrew and remove the safety shield.

2. With the ram in the down position (tooling closed), loosen the #10-32 SHCS until the insulation punch (I2)

is free.

3. Rotate the insulation adjustment cam so the arrow points to the desired setting (“L”, “M”, or “S”).

4. With the ram in the down position, push the insulation punch (I2) up and tighten the #10-32 SHCS. Be

certain the ram maintains the full down position while pushing up the insulation punch (I2) and tightening
the screw. It is important to keep the conductor punch (E2) butted against the conductor anvil (E1) while
locking the insulation punch (I2) in place.

5. Replace the safety shield and secure in position with the thumbscrew.

MOUNTING SCREW

DIAMETER WIRE INSULATION

ADJUSUSTMENT

HOLDER

LARGE DIAMETER
WIRE INSULATION

THE MOST UPWARD POSITION IN

THE PUNCH HOLDER

THE MOST DOWNWARD POSITION

IN THE PUNCH HOLDER

SMALL DIAMETER
WIRE INSULATION

2.7. Die Spacer Installation

Die spacers are required for certain tape-mounted products. For example, products with large ring or
spade configurations require the crimp tooling to be repositioned for proper termination. To install a die
spacer set, follow the instructions in Section 2.4 Crimp Tooling Installation and Removal and refer to the
Crimp Tooling Specification Sheet when necessary. Die spacers are always positioned behind the
required crimp tooling (See Figure 2.4) and will require longer crimp tooling mounting screws. A variety of
screws are provided in the fastener kit supplied with the machine.

CAM

Order No: TM-192280498 Release Date: 11-11-02 UNCONTROLLED COPY Page 12 of 42
Revision: E Revision Date: 08-25-09

ATP-301 Air Tape Press

3.1. Control Panel Operation

3.2. Loading Taped Product

3.3. Removing Taped Product

3.4. Wire Stop Installation

3.5. Stripper Installation

Section 3

Setup-Operation

Order No: TM-192280498 Release Date: 11-11-02 UNCONTROLLED COPY Page 13 of 42
Revision: E Revision Date: 08-25-09